Study and Characterization of Polyvinyl Alcohol-Based Formulations for 3D Printlets Obtained via Fused Deposition...

Area of Science:

• Pharmaceutical Technology
• Materials Science
• Additive Manufacturing

Background:

• Three-dimensional (3D) printing offers a novel approach for creating customized pharmaceutical dosage forms and medical devices.
• Polyvinyl alcohol (PVA) is a key material for 3D printing medicines via fused deposition modeling (FDM), integrating hot melt extrusion and 3D printing technologies.

Purpose of the Study:

• To identify the most suitable PVA grade and plasticizer for 3D printing personalized medicines.
• To investigate the impact of filament drug loading and tablet infill on the drug release profile of 3D printed paracetamol formulations.

Main Methods:

• Screening of three PVA grades, with selection based on molecular weight and plasticization with sorbitol.
• Characterization of materials and filaments using X-ray powder diffraction (XRPD), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC).
• Assessment of polymer melt printability via complex viscosity measurements and application of factorial design to analyze drug release kinetics.

Main Results:

• Partially hydrolyzed PVA (MW 31,000-50,000) plasticized with sorbitol demonstrated optimal printability.
• 3D printed tablets (printlets) with 40% infill showed immediate drug release, while higher infills resulted in prolonged release.
• Factorial design analysis and Pareto charts confirmed that tablet infill significantly influenced the dissolution rate at 45 minutes.

Conclusions:

• Optimized PVA formulations are suitable for FDM-based 3D printing of personalized medicines.
• Tablet infill is a critical design parameter for controlling the drug release rate in 3D printed dosage forms.
• This study provides a foundation for developing patient-specific 3D printed medications with tailored release profiles.